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CONTENTS
1. General
2. Design and Function
2.1 General
2.2 Inlet box
2.3 Impeller casing
2.4 Impeller
2.5 Shaft and bearing
2.6 Diffuser
2.7 Motor
2.8 Pitch control system
2.8.1 Design
2.8.2 Control mechanism
2.8.3 Positioning sensing
1. GENERAL
The axial-flow PFS(Propeller Fan with Single impeller) fan service as a forced draught(FD) fan for a boiler in a power plant application. Main component parts of the fan are :
1. One inlet box
2. One impeller, fitted with a casing
3. One diffuser
See figure1.
The main shaft is via a flexible coupling connected to a direct-drive electric motor (Supplied by ALSTOM).
The infinitely adjustable impeller blades permit control of the air flow through the fan while the fan is in operation. In boiler applications the purpose of this electro-hydraulic pitch control system is to maintain a vacuum in or air-flow through the boiler
A sensor registers the pressure (actual value) at the location selected and transmits a corresponding signal to a regulator. (Note the sensor and regulator is not in the scope of ABB SEFAN) The regulator is set for the flow required (ordered value). If actual and ordered values do not coincide, a corrective signal is transmitted to the electronics in the control cabinet causing it to actuate the proportional valve. Thus the blade pitch is changed to make the actual value coincide with the ordered value.
Figure2 illustrates how the pitch control system is employed.
The hydraulic unit supplies oil at a constant pressure to the proportional valve. From the proportional valve the hydraulic oil is directed to a hydraulic cylinder which actuates the mechanical components of the pitch control system, thereby changing the angle of the impeller blades. This change causes the air flow through the fan to change.
When the fan is in operation the two shaft supporting bearings are lubricated by circulating oil also supplied by hydraulic unit. Sensors are fitted in the bearings to facilitate the monitoring and supervising of temperature and vibrations.
2. DESIGN AND FUNCTION
2.1 General
Figure3 shows the FD-Fan and its main components parts.
All static parts of the fan, e.g. inlet box, impeller casing and diffuser are of fabricated design and bolted together. The rotating parts are made from forgings, castings and fabricated details. The impeller blades are made of sand-cast aluminium whereas other parts are fabricated mainly in steel and spheroidal graphite cast iron.
Access doors are provided for the purpose of inspection and service of the fan. Lifting eyes and rollers are fitted to facilitate maintenance. The roller-device is used at withdrawal of the diffuser from the impeller casing for overhaul of the impeller.
The entire fan installation is insulated mineral wool to reduce noise and heat radiation from the fan.
2.2 Inlet box
As shown in figure4 the inlet box is designed to deliver an evenly distributed air flow over the entire impeller. This is accomplished by means of the aerodynamic shape of the inlet box and guide vanes fitted in the outlet. The inlet box is supporting one end of the bearing assembly by a flange connection and transfers the shaft forces to the foundation.
Access doors facilitates inspection and service of the box and entrance to the central part for lubrication of the impeller bearings and inspection of the bearing assembly.
A lifting eye fitted in the central part of the inlet box is intended as a lifting attachment in conjunction with installation or removal of the bearing assembly.
2.3 Impeller casing
The impeller is enclosed in a protective casing, see figure5. A bolted access door is provided to facilitate replacement of impeller blades.
Inside surface of the casing are machined in ordered to achieve a minimum of impeller blade tip clearance.
2.4 Impeller
Figure6 shows the design and component parts of the impeller which basically consists of a fixed and moving part as follows :
· The fixed part comprising
- Hub, secured onto the shaft by means of a keyed shaft and an end washer.
- Hub rim for attachment of the blade shafts.
- Impeller fairing section.
- Impeller disc, for covering and protecting the internal moving parts of the impeller.
· The moving part comprising.
- Axially adjustable control disk.
- Control arms, attached to the control disk. The other end of each control arm is connected to the respective blade holder by means of an eccentrically supported control stud.
- Blades with blade holder and bearing.
- Control mechanism consisting of hydraulic cylinder and parts transferring the movement.
As earlier mentioned the pitch of the impeller blades is infinitely adjustable from the minimum to the maximum position while the fan is in operation. Axial motion of the control disk is transformed by the control arms and their studs into rotary motion of the blade holders.
2.5 Shaft and bearings
The shaft onto which the impeller is fitted is supported by two spherical roller-bearings in a common housing, see figure7. The bearing closest to the motor, the pilot bearing, takes up both axial and radial forces while the other bearing, the non-locating bearing, takes up radial forces only. The bearings are fitted directed onto the shaft.
Both bearings are lubricated by forced lubrication from a common lubrication and hydraulic system. (Hydraulic unit)
A single vibration sensor is fitted to the non-locating bearing for monitoring of the horizontal vibrations. The sensor is connected to a monitor located in the control cabinet. The monitor has relay outputs for alarm/trip circuits set at two different levels.
The bearing temperatures are monitored by means of temperature sensors.
The fan shaft is connected to the motor shaft via a flexible coupling.
2.6 Diffuser
The purpose of the diffuser, figure9, is to obtain an even and undisturbed reduction of the gas velocity and transforming it back to static pressure. This is accomplished by the guide vanes and the gradually increasing diameter of the diffuser. The central part of the diffuser contains a rotating union connected to the hydraulic cylinder for the pitch control system and a linkage system which transfers the motion of the control mechanism to an electrical position sensor.
2.7 Motor
Supplied by ALSTOM
2.8 Pitch control system
2.8.1 Design
Figure10 is an overview of the pitch control system and its main component parts :
The positioning of the control mechanism is determined by changing the direction of the hydraulic oil which reaches the piston rod by way of the rotating union. In the center of the piston rod there are two passages from which the oil is directed into the hydraulic cylinder via two parts on the piston rod.
One end of the piston rod is attached to the control disk by means of a flange and three control rods.
2.8.3 Position sensing
The position sensor, shown in figure12, consists mainly of a linkage system and a control box.
The linkage system transfers the axial motion of the control mechanism to a capacitive position sensor in the control box. The box also contains two limit switches which are actuated when the control mechanism reaches the respective end position.
Control cabinet
The control cabinet contains the electronic equipment of the pitch control system, the vibration monitor, etc. see also the chapter entitled “Electrical drawings”
INSTALLATION INSTRUCTION
FD FAN PFS-265-112
CONTENTS
1. PRECAUTIONS FOR STORAGE OF PF FANS
2. GENERAL
2.1 FOUNDATION
2.2 PREPARATIONS
2.3 ASSEMBLY
2.3.1 Inlet box, motor base and bearing assembly
2.3.2 Impeller
2.3.3 Motor, Impeller casing
2.3.4 Diffuser
2.3.5 Motor coupling alignment
2.3.6 Hydraulic system
2.3.7 Inlet support, Transition, Silencer and Inlet hood
2.3.8 Ancillary equipment
2.3.9 Final steps
2.4 PRE-COMMISSIONING
2.4.1 Oil flushing
2.4.2 Check of safety and control system
2.5 APPENDICES
2.5.1 Erection report
1. PRECAUTIONS FOR STORAGE OF PF FANS
The following instructions for storage also apply for the installation and commissioning period
1.
a) Keep all parts of the fan rotor in a dry room with a relative humidity below 65%
b) Keep all rotor parts under roof in drip-proof casings. The casing must be contain bags with desiccants. The bags must be replaced according to instructions from the bag manufacturer.
2. The main shaft must be rotated by hand a few revolutions once a month. If the bearing assembly is stored in a casing, the shaft must be accessible through an opening with a cover
3. The hydraulic unit must be
a) Stored according to item1 above, or
b) Kept under roof and well filled with oil.
4. All oil pipes, weather separate or assembled inside the diffuser, must be plugged in both ends. This is also applicable to the hoses.
5. The proportional valve shall be kept in its original package and stored under roof.
6. The control cabinet shall be kept in its original package and stored under roof until installation. After installation the cabinet must be protected until the anti-condensation heater is connected. Always keep door closed when no work is carried out.
7. Special care must also be attended to the positioner cabinet and the instruments. Store under roof.
8. Fan casing and other static parts must be protected from rain and condensation. Place parts in positions to avoid rain water filling. All machined parts must have a protective coating of wax, e.g. Tecty1, Dinitrol e.t.c.
9. For parts supplied in containers, we recommend to keep all parts inside the container until it is time for installation of the parts.
10. When storing equipment outdoors always place the parts on crossbars to avoid parts to be in direct contact with the ground.
11. Always keep parts stored outdoors free from dirt and sand as clean surfaces are more corrosion resistant.
12. Handle equipment with care to avoid distortions and painting damage as much as it is possible. Avoid lifting direct by fork lifters – use slings and eye bolts.
2. GENERAL
For the proper installation we recommend all customers to order an erection supervisor from ABB Ventilation Products AB for the entire installation period of for the critical parts of it.
The following drawings are required for proper installation of the fan :
(All documents are part of the O&M manual)
GA drawing, General assembly drawing, Hydraulic and lubrication system, Impeller assembly drawing, Hydraulic cylinder, Holding brake assembly, Positioner mechanism, Positioner cabinet, Flow monitoring equipment, Vibration monitoring equipment, Temperature detector, Tool box, Inlet expansion joint, Outlet expansion joint, Inlet support, Silencer assembly, Inlet hood, Hydraulic unit pitch control, PI-diagram
All documents references below will be according to the list above.
The fan is erected directly on a concrete foundation. Dimension and details of the foundation will be found on the General Arrangement Drawing and under the headline “Foundation” below
When cutting pipes tubes always use special cutting tool to avoid iron fillings penetrating the tubes.
Never bend tube by means of heating – use tube bending tools suitable for the dimension of tube
Fit sealing plugs and caps during the progress of the pipe installation work to prevent contamination of the hydraulic and lubrication system during installation.
Please note that the precautions for storage of the fan parts must be observed during the entire installation and commissioning period.
Check and sign off according to the “Erection Report” see appendices fill in this report subsequently.
2.1 Foundation
At design and grouting of the foundation all requirements and information given of the Fan General Arrangement drawing must be followed with special attention to the following :
· Foundation plan(see GA)
· Required dimension of the foundation with regard to fan loading and and applicable local building code or specifications from the client or his building engineer
· Box outs for the foundation bolts must be formed.
· Frequency calculation must be performed to avoid primary resonances.
Please see information on GA.
· Cast in flat bars for shimming. The slide rails for withdrawal of diffuser will be cast in at the grouting later. Especially note that cast in flat bars have to be connected to the reinforcement or to be provided with tie-down bars.
· Plinths for control cabinet and hydraulic unit.
· Make provisions for steps up to the foundation for the daily maintenance as required.
· For the final grouting of the boxed out holes and up to final level expanding concrete of quality K50 or better to be used.
After grouting inspect and verify that the finished foundation is according to the foundation drawing and the GA drawing requirements. Make sure the upper side is plane within normal building tolerance (+/- 10mm), the boxed out holes are correctly located as well as the flat bars and the slide rails.
Also check dimensions with regard to references for elevation, lateral and longitudinal position in the building.
2.2 Preparations
Figure1 gives a general view of the fan identifying its main component parts. Please refer also to the General Arrangement and Fan Assembly Drawings for further information.
1. Make sure inspection and approval of the foundation after grouting has been made and that it is verified.
2. Check the datum positions for elevation and lateral and longitudinal positions. Together with clients representative set positions for the fan shaft centerline in elevation and lateral position and the inlet duct centerline position. For the measurements use theodolite and/or other suitable instruments.
3. Make sure all necessary documents are available and are of the latest revision.
4. Make sure all necessary tools and lifting equipment are available.
· Crane for lifting(suitable for the actual required lifting capacity and service range). Fixed equipment as well as mobile crane may be suitable.
· Lifting tools (slings, jacks, winches, hoists, hooks, eyes etc). Make sure they are approved and suitable for the capacity required.
· Ordinary hand tools.
· Special tools. Included in the delivery, see drawing V1618368.
· Tube bending and cutting tools for diameter 15 and 22mm.
· Dynamometric wrench for the required torque.
· Tools for measurement : level gauge, plummet line, gauge rod, sliding caliper etc.
· For alignment of the coupling laser equipment of suitable indicator gauge.
5. Clean up the concrete foundation and the surrounding area. Ensure that the boxed out holes for the foundation bolts are clean and free from water and foreign objects.
2.3 Assembly
2.3.1 Inlet box, motor base and bearing assembly
1. Take in the following parts : Inlet box, motor base, bearing assembly, foundation bolts, shim plates, fan half coupling and the required assembly details.
2. Please refer to fig2 and the GA drawing. Place the foundation bolts(5), with only the lower nut mounted, in their respective boxed out holes of the foundation according to the GA drawing.
3. Please refer to fig2. Place the inlet box(1) and the motor base(4) on the 25mm plates on top of the cast-in flat bars(7), on the foundation. The following shim plate dimension are provided : 1,2,5,10 and 20mm by using the shim plates, align the inlet box to the FD Fan C/L level according to the GA drawing and earlier set out. With suitable shim plates, also make sure that the impeller end flange of the inlet box is vertical within ± 1mm. Make the final check on the connection flange for the bearing assembly. This flange must be as near vertical as it is possible to align it. It is also very important that the inlet box is laterally correctly positioned and aligned and that the inlet is in line with the centerlines for the inlet duct set out.
4. Align the level of motor base(4) by adjusting the shim plates. Align the motor base axially to match the position of the bearing assembly feet and center it sideways. Make sure that the upper surfaces of the motor base are in level within ± 1mm.
5. Fit the fan coupling half on the bearing assembly shaft end. Before fitting, thoroughly clean the surfaces of the shaft end and the coupling bore with white spirit or similar. Apply Molycote BR2 or equal grease on the surfaces before fitting. If it is not possible to fit the coupling half without heating, heat up coupling half carefully evenly and fit the coupling. Do not forget the key.
6. Prepare the bearing assembly(3) for mounting, by installing the lubricating system fitting and tubing(2). Clean up the tubes with compressed air before they are connected and plug openings with plastic caps afterwards. For specific detail, refer to the Hydraulic System Drawing.
7. Lift the bearing assembly(3) into the inlet box. A lifting lug fitted in the central part of the inlet box is intended as a lifting attachment in conjunction with installation or removal of the bearing assembly.
8. Fit the bearing assembly(3) onto the flange provided in the inlet box and the pedestal on the motor base. Verify that the C/L of the shaft is concentric with the cylindrical part of the inlet box and is horizontal. If necessary re-adjust the shim thickness of the motor base. Also measure the axial position of the bearing assembly to verify that the clearance between impeller rim and inlet box meets the requirement specified on the Fan Assembly Drawing. Do not fit the position of the bearing assembly with the tapered pins at this stage. Further adjustment be necessary later.
9. When the alignment as per item 8 is satisfactory, mount the upper nuts on the foundation bolts and tighten it against the foot plate(Torque 140Nm). The bolt threads shall protrude about 10mm over the upper nuts.
10. Use expanding concrete(quality see headline foundation) and make the first grouting, for inlet box and motor base, up to the level(8) in figure2. No grouting on inside of the surrounding tube of the foundation bolts. Let the grouting harden. For hardening time please refer to the documentation for the grouting cement.
11. When the grouting has hardened, screw the lower nuts down about 10mm on the foundation bolts and tighten the upper nuts to pre-tension the foundation bolts. First torque 140Nm, and then to 200Nm. Finally re-check the alignment. Adjust as necessary.
12. Complete the lubricating tube installation. Clean the tubes with compressed air before connection and plug open tubes afterwards.
13. Fit the sealing ring(1, figure3) onto the inlet box, concentric to the fan shaft within ± 0.2mm.
2.3.2 Impeller
See figure3
1. Fit the lifting eye(2) onto the blade holder closet to the key-way of the impeller hub, and the lifting eye(5) onto the impeller hub. The lifting eyes are to be found in the tool box if not already fitted on the impeller.
2. Clean the shaft and impeller bore thoroughly by white spirit or similar. Coat the shaft(4) with Molycote BR2 or equal. Fit the key(3).
3. Lift the impeller into position for mounting onto the shaft. Lift the impeller in the lifting eye on the hub. Then raise the impeller into vertical position with the lifting eye on the blade holder.
4. Fit the impeller into the shaft suing the mounting tools in the tool box(see Tool Box Drawing). Secure the impeller with the shaft end plate(see Fan Assembly Drawing).
5. Re-check the bearing assembly to inlet box alignment and check the clearance between the impeller rim and inlet box. Dimensions are stated on the fan assembly drawing. If dimension is outside the clearance this must be adjusted immediately at this stage by placing washers between the bearing assembly and the inlet box flange. If unclear please consult ABB Ventilation Products AB before continuing erection.
6. Remove the lifting eyes from the impeller and put them back into the tool box.
7. Fit the impeller blades onto the impeller. Note that blades and the blade holder are stamped with numbers in numerical order. Each blade to be fitted in the blade holder with the same number. Fit screws and washers and tighten with the torque specified on the Impeller Assembly Drawing.
2.3.3 Motor, Impeller casing
1. Lift the motor, motor half coupling, impeller casing, hydraulic cylinder and the necessary assembly details.
2. If not already done, fit the coupling half on the motor shaft according to item 5 for the chapter inlet box etc above.
3. Place the motor on the motor base and make a preliminary fans to motor coupling alignment check to verify that no major adjustment(elevation +0/-1mm, other ± 1mm) of the motor base position is necessary.
4. If no further adjustment are necessary, remove the plastic caps of the tubes surrounding the foundation bolts and use expanding concrete to make the final grouting for the inlet box and motor base.
5. When the grouting has hardened, re-tighten all foundation bolts(200Nm). For hardening time please refer to the documentation for the grouting cement.
6. Fit the impeller casing(6, figure3). Apply tightening strips between the flanges. Fix the tightening strips with silicon glue during the erection.
Important ! The strips must be applied carefully in order to avoid leakage between the flanges. Adjust the casing so that the tip clearance all the way around is within the limits given on the fan assembly drawing.
Important ! To simulate the centrifugal force, while the tip clearance is being verified, the blade subjected to measurement shall be pressed outwards as far as the axial play of the blade bearing permits (e.g. by wedging in a pair of screwdrivers between the impeller fairing and the blade root, one on each side of the blade base) and hydraulic cylinder V8507990.
7. Fit the Hydraulic Cylinder. Refer to the Impeller Assembly Drawing V8508337. Tighten the screws in the impeller hub with the torque specified on the drawing.
8. Fit the cylinder flange temporarily on the spacer. (The blade angle will be adjusted when pre-commissioning).
2.3.4 Diffuser
1. Lift the Diffuser and the necessary assembly detail.
2. Place the foundation bolts in their respective holes of the concrete foundation acc. to the Fan Outline Drawing(see Dwg list).
3. Install the diffuser onto 25mm shim plates. Fit and tighten the foundation bolts against the diffuser foot plates (100Nm). Also fit the slide rail before grouting. The slide rails must be pressed up to towards the diffuser foot plates (G-clamp or similar) and be located acc. to the GA Drawing, elevation and section A-.
4. Refer to the Fan Assembly Drawing and verify the axial play between diffuser and the impeller. If necessary loosen by grinding the tack welds of the diffuser inlet flange to adjust the play before making the final welding. Adjustment of elevation is made by fitting suitable shim plates. Make sure the diffuser is in line with the earlier installed parts.
5. When the alignment is satisfactory (no tolerances are given – make as good as possible), make the final welding of the diffuser inlet flange acc. to the Fan Assembly Drawing.
6. Apply tightening strips between the flanges-use silicon glue or corresponding and apply the strips carefully to avoid leakage between the flanges. Tighten the flange bolts and verify the axial play between impeller and diffuser.
7. Use expanding concrete and make the final grouting up to the lower side of the foot plate and the slide rail acc. to the Fan Outline Drawing. Let the grout harden. For hardening time please refer to the documentation for the grouting cement.
8. When the concrete has hardened tighten the foundation bolts to 200Nm.
9. Fit the sealing ring between the diffuser sealing cone and the impeller acc. to the Fan Assembly Drawing. Do not forget the gasket.
2.3.5 Motor coupling alignment
1. The coupling halves have been fitted to the fan and motor shaft at an earlier stage
2. For the alignment use laser equipment of if not available indicator gauge. Place suitable shims between the motor feet and motor base and align the coupling. Note these shims are delivered together with motor. Permissible radial and axial run-out are 0.05mm indicator reading. The axial play between the coupling halves is specified on the Fan Assembly Drawing. The motor is aligned sideways by the jacking screws provided on the motor base, and vertically by using the motor jack screws and adjusting the thickness of the shims between the motor and the motor base. Assembly instructions for the coupling are found in the O&M Manual under “Component Descriptions”.
3. Refer to the Fan Assembly Drawing. When all alignments acc. to the drawing are satisfactory, drill the holes required and fit the dowels between the impeller casing and the inlet box, and between the impeller casing and the diffuser.
4. Then drill and ream the holes required for the dowel pins at the motor end of the bearing housing acc. to the assembly drawing. Also drill and ream the holes for and fit the dowels for the motor. These dowel are supplied with the motor.
5. Fit the brake and speed sensor acc.to drawing V1618389.
6. Fit the coupling guard.
2.3.6 Hydraulic system
1. Locate and fix the hydraulic unit as shown on the General Arrangement Drawing. The hydraulic unit is delivered with a flushing plate instead of the proportional valve. The flushing plates is only used during the flushing procedure.
Note : For the piping installation it is important to :
a) Cut the tubes using a tube cutting device.
b) Lightly de-burr the inside and outside edge of the pipe ends.
c) Do not chamfer the pipe ends.
d) Check that the tubes are clean before erection.
1. Install the hydraulic system as specified below and as shown on the Hydraulic System Drawing.
2. Fit the hydraulic and lubrication systems components and lines acc. to Hydraulic System Drawing, excluding the hoses to the rotating union which will be fitted at a later stage.
3. Make electrical connections acc. to the wiring diagrams supplied.
4. Fill the hydraulic tank with flushing oil Shell Tellus S22 or equivalent
2.3.7 Inlet support, Transition, Silencer and inlet hood
1. Erect the inlet support acc. to the Inlet Support Assembly drawing, and adjust the level on the connection plate on the support.
2. Use expanding concrete and make the final grouting up to the lower side of the foot plate acc. to the Fan Outline Drawing. Let the grout harden. For hardening time please refer to the documentation for the grouting cement.
3. When the concrete has hardened tighten the foundation bolts to 700Nm.
4. Assembly the transition acc. to the Transition Assembly drawing and lift it in place on the inlet support.
5. Assembly the silencer casing acc. to the Silencer Assembly drawing.
6. Install the baffels in the silencer casing. Handle the baffels carefully.
7. Lift the complete silencer in position and fit it on the transition.
8. Erect the inlet hood with roof acc. to Inlet hood assembly. Lift the complete inlet hood in position and fit it on the silencer.
2.3.8 Ancillary equipment
1. Refer to suppliers documentation and fit the expansion joints at the fan inlet and outlet.
2. Install the flow monitoring system according to drawing for the system.
3. Fit the Vibration Detector and Temperature Detectors acc. to the corresponding drawing in the drawing list.
4. Fit the positioner system according to the Positioner Mechanism and Positioner drawings and adjust it acc. to the Installation, Pitch Control System drawing.
5. Locate the control cabinet and it to the plinth. See General Arrangement Drawing.
6. Refer to the Electrical Drawings supplied and connect and support all cables between the fan and the cabinet. Note the vibration monitoring cable is a special cable included in the supply. All other cables are not supplied by ABB Ventilation Products AB.
Important ! Connect the control cabinet heater as soon as possible and keep on, always keep the cabinet door closet when no work inside is in progress.
2.3.9 Final steps
1. Remove the stays in the inlet box inlet section.
2. Clean the inside of the fan. Ensure that no tools or foreign objects are left inside the fan or in the ductwork upstream of the fan.
3. Clean all damaged or corroded surface and make touch up painting according to painting procedure V5003312.
4. Fill in and sign off the Erection Report.
2.4 Pre-commissioning
2.4.1 Oil flushing
1 Make a temporary by-pass for the rotating union inside the diffuser, by connecting one of its hoses to both connections on the hydraulic feed pipes for the rotating union. Divert the oil feed to the bearing housing directly to the outlet by loosening the feed pipes and the outlet hose from the bearing housing. Connect the feed pipe directly to the outlet hose by temporary plastic hoses (supplied with the Commissioning Consumables).
2 Start up the hydraulic unit (one pump only). Verify that the motor is running in the direction of the arrow on the motor and that the pump is giving pressure.
3 Flush the system in the way for 5hours. Ensure that no filters are by-passed(alarm) due to high oil viscosity (cold oil) or dirty oil.
4 Stop the hydraulic unit and turn the flush plates on the hydraulic unit 180°(changing the flush direction) and flush for 5hours further. The oil is now circulation in the opposite direction between the hydraulic unit and the fan.
5 When the flushing is complete stop the hydraulic unit and reconnect the feed pipes and outlet hose to the bearing housing.
6 Disconnect the temporary by-pass hose for the rotating union.
7 If fitted earlier, remove the rotating union from the hydraulic cylinder. Secure the rotating union in a wire and fit the three hoses on to the rotating union as shown in figure4.
8 Fit the rotating union onto the control mechanism. Ensure that the gaskets in figure4 above are seated properly.
9 Connect the hoses to the hydraulic pressure(2pc) and return(1pc) pipes. Refer also to the Hydraulic System Drawing.
10 Change the hydraulic oil in the hydraulic unit to Shell Tellus S68 or equivalent. Change those filters that were in operation during the flushing. New ones are part of the commissioning spares.
11 Start up the second hydraulic oil pump. Verify that the motor is running in the direction of the arrow on the motor and that the pump is giving pressure.
12 Fit the proportional valve instead of the flushing plates on the hydraulic unit. Save the flushing plate in the tool box.
13 Sign off in the pre-commissioning check-list.
2.4.2 Check of safety and control system.
1. Verify the operation of all interlocks and monitoring equipment. E.g : signals from switches are tested either by, where possible, activating the switch or by disconnecting cables from the switch. Vibration detector are checked by tapping the vibration pickup with e.g. a screwdriver handle. Thermal detectors are checked by remote reading of the ambient temperature.
2. Adjust the control system.
3. Sign off the pre-commissioning list.
2.5 Appendices
2.5.1 Erection report
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